Palsgaard® SA 6610 – The versatile industrial cake emulsifier

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Palsgaard SA 6610 –
The versatile industrial cake emulsifier
®
Palsgaard Technical Paper, November 2013
way to succeed
- let us help
you do
so.
By Peter Poulsen,
International Sales
Manager, Bakery
& Confectionery,
Palsgaard A/S.
I
n this article the benefits of
Palsgaard® SA 6610 will be examined. The focus will be on bakery trends and segments with high
growth, which are also the areas
where a high number of new developments are carried out. Finally,
the functional benefits of the emulsifier in industrial cake production
and Palsgaard’s bakery application service will be explored.
The versatility of Palsgaard® SA
6610 is founded in its ability to live
up to many claims which consumers find attractive – such as gluten
free, GMO free, healthier products
and leaner labels - as well as in its
functionalities designed solely for
industrial cake production.
Industrial bakeries constantly face the challenge to
either follow or stay ahead of the trends in the bakery
market. Keeping up with consumer demands calls
for a steady stream of new developments ready to
be launched. One of the keys to staying ahead of
the market is having versatile ingredients available
for fast product development. Equally important is
it that the ingredients involved can be used for new
market entries. Being forced to find new ingredients to
overcome market barriers in new markets is very time
consuming and can delay new product development
substantially. Having a versatile cake emulsifier such
as Palsgaard® SA 6610, an activated cake emulsifier
developed especially for industrial cake production
means that new product development is facilitated.
What is an activated
cake emulsifier?
Activated cake emulsifier is a term
used to describe the instant properties of Palsgaard® SA 6610 when
adding the product to the cake batter. The activation is achieved by
placing the emulsifier on the surface of very small starch granules
by means of an extrusion process.
The emulsifier on the surface of
the starch granule has to be in a
Figure 1. Microphoto of a powder particle of Palsgaard SA 6610
®
stable alpha crystal form as this
special crystal form is essential for
proper aeration of a cake batter. In
Figure 1 a micro photo of a powder
particle of Palsgaard® SA 6610 is
shown. You can identify the individual small starch particles in the
powder particle and each of these
starch particles is covered by a
monomolecular layer of Polyglycerol Ester.
This creation of a huge surface
area is achieved by means of our
special extrusion process. The result is very significant – one single carton of 15 kilos will have a
surface area equal to four to five
football fields. This fact is the background for the high efficiency of
Palsgaard® SA 6610.
The alpha crystal form in
Palsgaard® SA 6610 is stable for
min. 18 months - contrary to many
gels which may recrystallize quickly during storage creating white
spots. White spots in gels are not
whipping active and will spread
through the gel over time destroying whippability. This disadvantage will be avoided when using
Palsgaard® SA 6610.
Palsgaard Technical Paper - November 2013
Palsgaard® SA 6610 - The versatile industrial cake emulsifier
2
Following the market movers
Gluten free
Gluten free products are one of the
fastest growing segments within
the bakery industry. More and
more people are diagnosed with
gluten intolerance, and the number is expected to keep growing
in regions traditionally using wheat
and other grains containing gluten
in many products. Even consumers not suffering from gluten intolerance also choose gluten free
products for health reasons. As an
answer to the increasing number
of consumers looking for gluten
free products on the supermarket
shelves the Food and Drug Administration (FDA) in USA has recently
set down regulations as to what
can be labelled gluten free.
Palsgaard® SA 6610 fits well into
the development of gluten free industrial cake products. Palsgaard®
SA 6610 consists of one emulsifier
and one activating medium. The
emulsifier is a Polyglycerol Ester
(PGE), and the activating medium
is rice flour. All ingredients have
gluten free status. Bridging the gap
from idea to market with a gluten
free product is not just about one
ingredient. Palsgaard can support
in creating gluten free formulations, and help with knowledge of
gluten free ingredients to secure
successful gluten free cake products.
also a push for producers to manufacture non-GMO products. Some
producers have already answered
the market by reformulating products into non-GMO products.
Palsgaard® SA 6610 consists of
ingredients only with non-GMO
status. With this emulsifier the
producer has one less ingredient to worry about if the pressure
against GMO ingredients keeps increasing. Having ingredients with
a non-GMO status also makes
product development easier when
targeting markets where consumers avoid buying cakes containing
GMO.
Health concerns
Even with cake - considered to be
a product for indulgence - there is
in many countries and regions a
growing consumer push for producers to formulate healthier cake
products. In some countries it is
consumer driven, while in other
countries healthier snacks and
cakes are demanded by the politicians through regulations.
Palsgaard® SA 6610 fits well into
this globally growing trend. The
emulsifier offers functionalities that
support the industrial manufacturer when formulating new cakes. A
real benefit is that Palsgaard® SA
6610 is able to hold high amount
of liquid vegetable oil in the cake.
This means easy transition for
cake manufacturers wanting to
reformulate away from a fat system containing one or more less
healthy vegetable fat types. It
could be fat containing trans fatty
acids, high in saturated fats or
hydrogenation. Removing these
fats and replacing them with fats
which are high in unsaturated fatty acids like liquid vegetable oil,
will mean that the cake will become healthier. On the plus side,
Palsgaard has even seen that this
reformulation leads to cakes with
more juiciness as well as improved
softness throughout storage on the
supermarket shelves.
Switching to Palsgaard® SA 6610 will allow the manufacturer to use healthier,
liquid oils – leading to softer, juicier cakes throughout the entire shelf life of the
cakes.
GMO free
Food products containing genetically modified organisms (GMO)
have always been a hot topic. In
some regions consumers and politicians have decided against food
products containing GMO, while
other regions like USA has been
more open to using GMO ingredients in food products. However,
in the last couple of years there
has been a mounting consumer
push towards regulated labelling
of products containing GMO, and
Palsgaard Technical Paper - November 2013
Palsgaard® SA 6610 - The versatile industrial cake emulsifier
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Lean label
In most countries there is a strong
demand for cakes with leaner labels - meaning cakes with less additives and preservatives.
Palsgaard® SA 6610 can help
shorten the list of additives compared to other available industrial
cake emulsifier solutions. Most solutions require the manufacturer to
label 3-5 additives, while this product consists of only one emulsifier
and one activating food medium.
Palsgaard® SA 6610 can be considered a lean label industrial cake
emulsifier and offers cake manufacturers top of the class functionality and stability in production.
No allergens
Palsgaard® SA 6610 has no allergens according to Directive
2000/13/EC. It contains neither
milk, soy nor wheat proteins nor
any other allergens, and can therefore be considered allergen free.
The product is based on 100%
vegetable based raw materials and
is both Kosher and Halal certified.
All in all the above mentioned
characteristics of Palsgaard® SA
6610 means that it is an ideal solution for bakeries producing industrial cakes. Palsgaard® SA 6610 is
a solution for today but also a safe
choice for the future. No matter
what geographical area, whether
a stirred cake or a whipped cake
is required, or gluten free, etc. this
emulsifier has the versatility required in industrial cake baking.
New ideas – new cakes
Globally the industrial cake area
is a field that is on the forefront in
terms of the number of new developments that hit the supermarket
shelves each year. Consumers in
many markets demand that the
cake manufacturers don’t just offer
old cake developments, but also
present new cake types as well as
twists to old offerings.
Being a global emulsifier supplier
and supporting the industrial cake
industry in all regions of the world
Palsgaard has a unique insight
into local developments and trends
as well as into regional cakes not
known in other parts of the world.
This puts Palsgaard in a position to
support cake manufacturers with
exciting new ideas like a Mamon
cakes from Asia, Lamington’s - a
long-time favourite from Australia
or the hugely popular cup cake.
Palsgaard® SA 6610 has over
many years proven its functionality
in industrial baking in all regions.
Whether it’s used in hot or cold climates the emulsifier delivers the
same performance under different conditions in any whipped or
stirred cake recipe.
Working with cake manufactures the world over gives Palsgaard great insight in
to cakes not known outside their local region, but which could be just what consumers in other parts of the world are looking for – like this delicious Lamington’s cake from Australia.
Palsgaard Technical Paper - November 2013
Palsgaard® SA 6610 - The versatile industrial cake emulsifier
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Optimal production and cost
Ideal for automization
Unlike most industrial cake emulsifiers Palsgaard® SA 6610 comes
in powder form, making it easy
to incorporate the emulsifier into
fully automatized cake production
lines. A simple solution is a small
silo system with direct dosing into
the mixing step of the cake production. The advantage is that dosing
will be more accurate compared
to manual dosing. As there are
few human errors it will in the end
mean that the cakes will be more
consistent in quality due to more
accurate dosing. Automization will
also mean less production cost
and it will be easier to reach HACCP quality standards.
Experience easy mixing
Palsgaard® SA 6610 offers the industrial cake producer the chance
to optimize the mixing time and the
number of mixing steps needed.
We recommend a two step mixing
solution when using Palsgaard®
SA 6610: Step 1 – Add all dry in-
gredients (including the emulsifier) and liquid ingredients except
oil/fat to the mixer. Step 2 – when
Palsgaard® SA 6610 has been activated add all the oil/fat and then
mix at low speed to incorporate the
oil into the batter. These few steps
mean that many cake producers
will experience a less demanding
and time consuming mixing process. After activation the emulsifier
will ensure an ideal food matrix for
further processing in the aerator.
It is essential that the industrial
cake producer can rely on the cake
emulsifier to perform to the same
high and stable level each time.
This requires a strong emulsifier
that is able to withstand the extra
demanding conditions that an industrial cake emulsifier has to endure during mixing, pumping, aeration, baking and packing. During
these different steps there is a high
risk that the cake batter or cake will
not maintain the unchanged specific gravity and stability needed to
secure cakes according to the desired specifications in each cake
batch. Palsgaard® SA 6610 has
been designed with these special
and demanding conditions in mind
and offers a safe solution for all
whipped and stirred cake types.
Attractive
cost-in-use solutions
Palsgaard® SA 6610 offers a
strong cost-in-use solution for the
industrial cake producer due to
its low dosage. Also when considering the opportunity to have a
fully automated production, which
most other solutions do not offer.
Another strong point is the low
product development costs both
when formulating different cakes.
Palsgaard® SA 6610 can support
most product claims and it is generally accepted in most markets.
An important factor is its ability to
create cakes with consistent high
quality, which means increased
sales, brand recognition and continued consumer acceptance.
Switching to Palsgaard® SA 6610 will allow the manufacturer to optimize the
mixing time and reduce the number of mixing steps needed.
Palsgaard Technical Paper - November 2013
Palsgaard® SA 6610 - The versatile industrial cake emulsifier
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Strong industrial cake setup
Pilot plant setup
Being a dedicated supplier for the
industrial cake industry for many
years, Palsgaard has seen the
need for offering strong application
support and service to our customers. Palsgaard can offer trials
at small scale as well as industrial scale. Our pilot plants include
extensive application facilities
such as mixers, aerators, depositors and ovens - all on industrial
scale, meaning that customers
can benefit from testing and proving new recipes and processes
at Palsgaard’s application facilities. Our industrial scale pilot plant
helps us make realistic trials which
can easily be up-scaled to fit our
customers’ setup.
A significant part of our know-how
within industrial baking is based
partly on trials performed on our
industrial pilot plant and partly on
our general practical experience
gained through many years of work
done on many different cake lines
around the world. Palsgaard offers
theoretical and practical support
using your set up, ingredients and
working conditions as a starting
point. In this way Palsgaard helps
shorten the time needed from idea
to market success.
Learn more about
Palsgaard® SA 6610
Should you be interested in learning more about the possibilities
with Palsgaard® SA 6610 in your
recipes, or getting an idea about
your cost-in-use using this emulsifier, we shall be happy to assist
you. Please visit www.palsgaard.
com to locate your local Palsgaard
office for exploring the opportunities.
Our fully equipped industrial baking pilot plant in Denmark provides the best
basis for understanding the complex nature of industrial baking. The facilities
include premixer, buffer tank, aerator, depositor, two zones convection oven,
cooling conveyer and an automatic roller for Swiss rolls.
Palsgaard Technical Paper - November 2013
Palsgaard® SA 6610 - The versatile industrial cake emulsifier
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